System and method for automated finishing of interior surfaces

ABSTRACT

An automated interior finishing system utilizes an apparatus having an upper section for mixing material, and a lower section for conveying the material. The upper section has a mixing compartment and a separate washing/storage compartment. Each compartment has a hinged lid that forms an air-tight seal. The mixing compartment has a shaft with an auger for mixing compound with water. The lower section has a motor for driving a progressive cavity pump, which receives mixed material from the mixing compartment. The pump delivers a smooth and uniform supply of material through an external supply hose. The apparatus is used as one component of an overall automated interior finishing system and method for completing surface finishes. For example, one end of the supply hose is connected to the outlet end of the pump for delivering mixed material to a hand tool at the opposite end, such as a flat taper.

BACKGROUND OF THE INVENTION

[0001] 1. Technical Field

[0002] The present invention relates in general to improved interiorsurface finishing, and in particular to an integrated system and methodfor automatically finishing interior surfaces such as drywall, acoustic,and painted surfaces.

[0003] 2. Description of the Prior Art

[0004] Wallboard or drywall has become the dominant material in theproduction of interior building partitions. Interior building partitionstypically comprise a studwall of vertical support members or studs thatare spaced apart from each other in a parallel arrangement. The studsare used to support preformed panels or wallboards that are usuallyattached to the studwall with fasteners. A joint exists between adjacentones of the abutted wallboards.

[0005] In order to provide a continuous flat surface appearance to thewall, it is necessary to apply a finish to the joint between theadjacent panels. Finishing typically requires the build-up of multiplelayers of a mastic material or joint compound that is commonly referredto as mud. Mud is a paste-like substance that is formed by mixing apowdery compound with water. The blending of the joint compound into thepanel surface forms the desired flat and contiguous wall surface. Thebuild-up of mud in the joint area or “floating” comprises theapplication of a first layer of mud and the embedding of a wallboardtape such as paper or fiberglass tape in the first layer. Finally, oneor two more layers of mud are applied on top of the first layer/tape tocomplete the joint. The finishing of the joints is a time consuming andlabor intensive process, since it is generally necessary to wait 24hours between each application of mud in order to allow each layer todry. In addition, it is generally necessary to sand the joint area so asto produce a finish that matches the remainder of the wallboards.

[0006] It is convenient to use a container for the mud which may or maynot include means for supporting a roll of tape. Combination mud andtape devices guide the tape through the mud and dispense it from thecontainer at the desired length with the tape coated in the mud. Anumber of devices have been devised in attempts to more efficiently andeffectively dispense mud during the drywalling process. Some devices arepressurized to dispense the mud, while others require traditional manualapplication. Unfortunately, most prior art designs have not been fullyaccepted by the construction trade. In particular, air pressurizedsystems have been marginal at best as there is significant time lagduring dispensing, and a potentially uneven application.

[0007] The application of drywall mud can also require large pieces ofequipment including a mud tank that is hauled on trucks to the worksite. The equipment is routinely left outside the structure beingdrywalled. After each day's use, the equipment, particularly the mudtank, must be cleaned with pressurized water. This operation usuallyinvolves another piece of equipment.

[0008] Accordingly, a need exists for an automated interior finishingsystem, such as a drywall compound feed system, that provides a steadyand closely controlled flow rate of mixed material through anapplication fixture. Another need exists for an automated, positivedisplacement system, such as a mud feeder system, that has negligiblehesitation or lag time between the initial release of material throughthe applicator and the time at which the material reaches its steadystate flow rate. In addition, a need exists for a finishing system thatdoes not require clean-up of the apparatus and tools, and which is lesscumbersome and more portable.

SUMMARY OF THE INVENTION

[0009] One embodiment of an automated interior finishing system andmethod utilizes an apparatus having an upper section for material mixingpurposes, and a lower section for material conveying purposes. The uppersection has a large basin with a mixing compartment and a separatewashing/tool storage compartment. Each compartment has a hinged lid thatforms an air-tight seal. The storage compartment has a hose with a spraynozzle for dispensing a pressurized spray of water. The mixingcompartment has a mixer shaft with a modified ribbon auger for mixingcompound with water dispensed from jets located in the mixingcompartment. The lower section of the apparatus contains a motor fordriving a progressive cavity pump, which receives mixed material fromthe mixing compartment. A pair of water pumps are also mounted to thelower section and provide pressurized water to the upper compartmentsfrom a water tank. The pump delivers a smooth and uniform supply ofmaterial through an external supply hose.

[0010] The apparatus is used as one component of an overall automatedinterior finishing system and method for completing surface finishes.For example, one end of the supply hose is connected to the outlet endof the pump for delivering mixed material to a hand tool at the oppositeend, such as a flat taper. Many other combinations of tools andcomponents are possible for finishing surfaces, depending upon theparticular application required. In another embodiment, the automatedinterior finish apparatus has two pumping systems that allow twooperators to simultaneously use the device. In yet another embodiment,the automated interior finish apparatus has a single compartment formixing, clean-up, and tool storage. Each of these versions is capable ofbeing partially disassembled or broken down into two separate, lighterpieces with four easy steps.

[0011] The foregoing and other objects and advantages of the presentinvention will be apparent to those skilled in the art, in view of thefollowing detailed description of the preferred embodiment of thepresent invention, taken in conjunction with the appended claims and theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] So that the manner in which the features, advantages and objectsof the invention, as well as others which will become apparent, areattained and can be understood in more detail, more particulardescription of the invention briefly summarized above may be had byreference to the embodiment thereof which is illustrated in the appendeddrawings, which drawings form a part of this specification. It is to benoted, however, that the drawings illustrate only a preferred embodimentof the invention and is therefore not to be considered limiting of itsscope as the invention may admit to other equally effective embodiments.

[0013]FIG. 1 is an isometric view of one embodiment of an automatedinterior finishing apparatus constructed in accordance with the presentinvention.

[0014]FIG. 2 is a side view of a locking handle on the apparatus of FIG.1.

[0015]FIG. 3 is an exploded isometric view of an upper portion of theapparatus of FIG. 1.

[0016]FIG. 4a is an exploded isometric view of a mixing assembly of theapparatus of FIG. 1.

[0017]FIG. 4b is a sectional end view of the apparatus of FIG. 1.

[0018]FIG. 5 is an exploded isometric view of a lower portion of theapparatus of FIG. 1.

[0019]FIG. 6 is a sectional side view of a portion of a pump utilized inthe apparatus of FIG. 1.

[0020]FIG. 7 is a sectional side view of an end of the lower portion ofthe apparatus of FIG. 1.

[0021]FIG. 8 is a plan view of a control panel utilized by the apparatusof FIG. 1.

[0022]FIG. 9 is an isometric view of an end of the lower portion of theapparatus of FIG. 1 with handles retracted.

[0023]FIG. 10 is an isometric view of an end of the upper portion of theapparatus of FIG. 1 with the lids in an open position.

[0024]FIG. 11 is an isometric view of an end of the lower portion of theapparatus of FIG. 1 with handles extended.

[0025]FIG. 12 is a reverse isometric view of the upper portion of theapparatus of FIG. 1 with the lids in the open position.

[0026]FIG. 13a is an opposite isometric view of the apparatus of FIG. 1.

[0027]FIG. 13b is a partially sectioned view of a hose for the apparatusof FIG. 1. FIG. 14 is a reverse isometric view of the upper portion ofthe apparatus of FIG. 1 illustrating usage of a wash basin.

[0028]FIG. 15 is an isometric view of the apparatus of FIG. 1 inoperation.

[0029]FIG. 16 is an enlarged isometric view of the wheel assembly of theapparatus of FIG. 1 in operation.

[0030]FIG. 17 is an isometric view of a universal control handleutilized during the operation of the apparatus as shown in FIG. 15.

[0031]FIG. 18 is an enlarged isometric view of a lower portion of thehandle of FIG. 17.

[0032]FIG. 19 is an isometric view of a second embodiment of anautomated interior finish apparatus constructed in accordance with theinvention and having dual pump capability.

[0033]FIG. 20 is an isometric view of an end of a lower portion of theapparatus of FIG. 19.

[0034]FIG. 21 is an isometric view of an upper portion of the apparatusof FIG. 19 shown with the lids open.

[0035]FIG. 22 is an isometric view of a third embodiment of an automatedinterior finish apparatus constructed in accordance with the inventionand having a single compartment.

[0036]FIG. 23 is an isometric view of an upper portion of the apparatusof FIG. 22 illustrating a storage rack located within the compartment.

[0037]FIG. 24 is an opposite isometric view of the apparatus of FIG. 22.

[0038]FIG. 25 is an isometric view of the apparatus of FIG. 22illustrating an initial step of the disassembly thereof.

[0039]FIG. 26 is an isometric view of the apparatus of FIG. 22illustrating a second step of the disassembly thereof.

[0040]FIG. 27 is an isometric view of the apparatus of FIG. 22illustrating a third step of the disassembly thereof.

[0041]FIG. 28 is an isometric view of the apparatus of FIG. 22illustrating a final step of the disassembly thereof.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE PRESENTINVENTION

[0042] Referring to FIG. 1, one embodiment of an automated interiorfinishing base unit or apparatus 11 constructed in accordance with thepresent invention is shown. Apparatus 11 is one component of an overallautomated interior finishing system and method for completing surfacefinishes. For example, one combination of the tools and components ofthe automated interior finishing system and method is shown in FIG. 15.One skilled in the art will recognize that many other combinations oftools and components are possible for finishing surfaces, depending uponthe particular application required.

[0043] In the version shown, apparatus 11 may generally be described ashaving an upper section 13 for material mixing purposes, and a lowersection 15 for material conveying purposes. Upper section 13 has a rigidtubular mounting frame 17 that is preferably formed from schedule-40stainless steel tubing having an outer diameter of one inch. Frame 17has handles 19, 21 that extend beyond each end of a large trough orbasin 23 to provide multiple pickup points for apparatus 11. As shown inFIG. 3, basin 23 is mounted to frame 17 and divided into two chambers orcompartments: a large automated mixing compartment 25, and a smallerwash and tool storage compartment 27. A dividing wall 29 is located inbasin 23 between compartments 25, 27.

[0044] Each compartment 25, 27 is provided with an independent cover orlid, 31, 33 (FIG. 1), respectively. Each lid 31, 33 is pivotally mountednear the upper edge of basin 23 with a hinge. The perimeter of the innersurface of each lid 31, 33 is provided with a gasket 35 (FIGS. 3 and10), such as a hollow bulb seal. Gaskets 35 allow lids 31, 33 to formindependent, air-tight seals with their respective compartments 25, 27at the upper planar surfaces of basin 23 and wall 29, which aresubstantially flush with each other. As illustrated in FIG. 2, eachcompartment 25, 27 has a latching mechanism 37 on an exterior of basin23, including a combination or key lock 39, for selectively locking andcontrolling access thereto, and for providing tool protection. Inaddition, the mixing compartment 25 is automatically electricallyinterlocked for operator safety via the control panel, which will bedescribed in greater detail below.

[0045] Referring to FIGS. 3 and 14, storage compartment 27 is equippedwith a small diameter hose 41 having a spray nozzle 43 for dispensing apressurized spray of water. Nozzle 43 has fingertip controls foradjusting both the flow rate and the spray pattern of the water. Hose 41and nozzle 43 provide on-board tool clean-up in storage compartment 27.When storage compartment 27 is not being used for clean-up, it providesan additional air-tight tank for tool storage in apparatus 11. Thus, ifpreferred by the user or operator, the tools need not be cleaned upafter each use, but can be stored within the moisture-proof basin 23until their next use since the wet material remaining in the tools stayscompliant and will not dry out.

[0046] Mixing compartment 25 has a pair of nozzles or jets 45 for addingwater thereto. In the version shown, jets 45 are located on oppositeends of compartment 25 and only control the flow rate of the waterdispensed therein. Jets 45 allow water to be manually or automaticallyadded to the material in mixing compartment 25 and reduce viscosity. Ahose-to-tank connection provides simultaneous compound mixing andcirculation.

[0047] In addition to frame 17, a series of support members or channels47, 49 are also used for the structural support of apparatus 11. Inparticular, channels 47 help support a mixer shaft 51 that extendsthrough and is sealed to mixing compartment 25 on bearings 53. As shownin FIG. 4a, a pair of generally helical, modified ribbon mixers oraugers 55 are rigidly mounted to mixer shaft 51 for rotation therewith.Each auger 55 has a pair of mounting elements 57 with a fluted blade 59extending therebetween as shown. In the preferred embodiment, blades 59have a series of sculptured edges 61 with one-half inch radii thatsignificantly contribute to the mixing process. Each auger 55 also has asmooth-edged flat blade 62 (FIG. 12) joining axially adjacent ones ofthe mounting elements 57 for greater structural strength while mixing.

[0048] Each blade 59 also has a force plate 63 mounted thereto. Forceplates 63 are generally tangentially oriented relative to the innersurface of mixing compartment 25, but skewed slightly in two directions,thereby causing a higher downward force on the material. As illustratedin FIG. 4b, force plates 63 assist in feeding and forcing material intoa tank opening 65 in mixing compartment 25, and keeping the pump intakefully charged with material. This system also will remove most of thematerial from the tank, leaving very little to clean up at the end of anapplication. Ideally, tank opening 65 is located at the bottom of theaxial center of mixing compartment 25 (see FIG. 12) so that both forceplates 63 centrally align therewith. Together, blades 59 and forceplates 63 keep the material, such as drywall, acoustic, or paintcompounds, in a uniform consistency, and material is delivered to thetools in a smooth, regulated flow. The center feed allows augers 55 tobe rotationally reversed, which keeps the material from being overlyforced into the pump. The reversible augers 55 blend the material moreefficiently because there is a shear point between the augers and theends of the tank. Preferably, the material is blended before it leavesmixing compartment 25 in order to prevent pump jamming. Rotating augers55 in only one direction may result in unblended material entering thepump, which can block the pump intake and stop the flow.

[0049] Referring now to FIG. 7, mixer shaft 51 extends through one endof mixing compartment 25 into a shroud or console 67 where mixer shaft51 is mounted to channel 47 via bearings 53. The distal end of mixershaft 51 is coupled to a mixer drive motor 69 via drive mechanism 71such as a timing belt. Channel 47 has an air inlet 73 (see FIG. 3) thatallows mixer drive motor 69 to cool the electrical components in console67 as indicated by the arrows. Air flow exits through vents 75 at theback of console 67. This feature eliminates the need for an additionalcooling fan. The dual bearing support uses the mixer shaft 51 as part ofthe motor support structure.

[0050] As shown in FIGS. 8 and 10, a control panel 77 for apparatus 11is located at the upper end of console 67. Control panel 77 provides aconvenient, centralized location for operator ease and material control.Control panel 77 includes a main power switch 79 for the entireapparatus 11, and a mixer power switch 81 for actuating augers 55. Apair of water control switches 83, 85 control water flow to compartments25, 27 (e.g., jets 45 and nozzle 43, respectively). Material controlswitch 93 allows the operator to control continuous flow from eitherapparatus 11 (local) or a handheld tool (remote). A remote settingswitch 87 allows an operator to change a control handle switch from amanual or momentary operation where the control handle switch must bedepressed to allow material to flow. Instead, remote setting switch 87allows the operator to push the button once for on and once again tointerrupt flow without the need to continuously depress a switch,thereby relieving finger strain.

[0051] In the preferred embodiment, switch 81 is used to change thecontrol at the handheld tool from manual to automatic control. In theautomatic control position, a sensor at the tool sends an electricalfrequency to a signal conditioner. The signal conditioner changes thefrequency to a linear voltage that causes the DC pump drive motor 101(FIG. 5) to rotate at a speed proportional to the frequency generated.This means that the faster or slower the hand tool is used, that thefrequency change will alter the pump speed, thereby making the pump 103a metering device that is capable of delivering the correct amount ofmaterial to the application tool at all times. The system is backed upwith a manual control system that is operable in the event that theautomatic controls become damaged.

[0052] There are many ways to generate these frequencies. Preferably, aninductive proximity switch sends a pulse to the signal conditioner eachtime a gear tooth on the application tool comes in close proximity tothe sensor. Other devices and methods for achieving this functioninclude encoders, hall effect sensors, mechanical switches, and opticalsensors. In addition, there are many types of signal conditioners suchas microprocessor-based conditioners. However, a cut-off switch that isactivated at the end of a drywall tape run, or anon-microprocessor-based signal conditioner that follows the inputwithout an extended processing time after the input is terminated ispreferred.

[0053] In addition, control panel 77 provides intermittent rotation ofthe augers via switch 89 so that mixing only occurs when the pump is inoperation. After a pre-mixing of the material is complete via switch 91,this feature prevents the material from being over-mixed, which would bethe case if it was allowed to be continuously mixed. Thus, once thepre-mix is complete, apparatus 11 can be switched to intermittent wherethe augers are used to only charge the pump. Furthermore, all electricalcomponents are moisture-sealed in the non-conductive, durable console67. External re-settable fuses add safety and convenience. Note thatconsole 67 and control panel 77 are surrounded and protected by handle19 of frame 17.

[0054] Referring now to FIG. 5, an exploded view of the lower section 13of apparatus 11 is shown. The components of lower section 13 mount to apair of side channels 95 that are joined via end channels 97 and othermounting channels 99. In the preferred embodiment of apparatus 11, asingle motor 101 drives a progressive cavity pump 103 via a gearbox 105and timing belt drive 107, which are mounted to channels 99. An intakefitting 109 is mounted between pump intake 111 and the lower end of tankopening 65 (FIG. 4b) for receiving material into pump 103. A screen islocated between the pump and compartment 25 to catch any debris that mayfall into the tank. A pair of water pumps 113 are also mounted to one ofthe channels 99 for providing pressurized water to compartments 25, 27from a water tank 115 which locates between basin 23 and water pumps113. In combination, water pumps 113, water tank 115, nozzle 43, andjets 45 provide a complete on-board water system for the uses previouslydescribed.

[0055] The positive displacement pump 103 has a variable speed drivethat ensures a smooth and uniform supply of mixed material through anexternal supply conduit or hose (FIG. 13a). The delivery or flow ofmaterial through pump 103 is significantly enhanced by a pair of helicalor fan-type rotor agitators 119 (FIG. 6) that reduce jamming and providedebris-free, positive delivery of all types of compounds. In contrast,conventional pumps utilize simple pin retainer bushings that jam when,for example, an operator fails to fill the pump with water prior toadding compound. Without agitators 119, the un-mixed compound would beforced into pump 103 with force plates 63 and would not create enoughsuction to start the un-mixed compound into the progressive pumpchambers.

[0056] A wheel assembly is located at the bottom of lower section 15 forfacilitating transportation of apparatus 11. A mounting bracket 121 issecured to each side channel 95 for receiving a center pivot pin 123extending through a lever 125 on each side of apparatus 11. Thus, eachpin 123 allows its respective lever 125 to pivot thereabout (compareFIGS. 15 and 16). A pair of axles 127 extend through and join the endsof levers 125. A non-pneumatic tire and wheel assembly 129 is mounted tothe end of each axle 127 for a total of four wheels (two on each side)that work in tandem for improved maneuverability and balance. Theadditional lever advantage allows the wheels to roll over obstacles mucheasier than a single axle. Located inside channels 95 adjacent to eachof the wheel assemblies are a pair of keyed equipment storage slots 131(two per side). Each slot 131 can store, for example, one tool extensionhandle 137 (one shown partially stored in FIG. 11). Thus, apparatus 11can store up to four tool extension handles 137. Slots 131 are keyed asshown to better retain 137 while apparatus 11 is being moved ortransported.

[0057] In operation (FIG. 15), apparatus 11 is connected to anelectrical power supply (preferably AC) and water tank 115 is filledwith water from an external water source. If apparatus 11 is to be usedfor drywalling, drywall compound is added to mixing compartment 25 andan appropriate amount of water is dispensed from jets 45. Augers 55 arethen actuated to pre-mix the compound and water to a desiredconsistency. More water and/or compound can be added at any time. Whenthe mixed material is ready, pump 103 can be engaged to deliver themixed material to a desired location.

[0058] Apparatus 11 is used as one component of an overall automatedinterior finishing system and method for completing surface finishes.For example, as shown in FIG. 15, one end of supply hose 117 isconnected to the outlet end of pump 103 for automatically andcontinuously (if desired) delivering mixed material to a hand tool orapplicator at the opposite end. Preferably, hose 117 is 50 to 100 feetlong and has a diameter of ⅜-inch to ½-inch. Hose 117 is also providedwith a unique internal electrical cord 133 for distributing electricalpower from apparatus 11 to the applicator or hand tool at the end ofhose 117. Electrical cord 133 is a small diameter conduit that extendsthrough the hollow inner diameter of hose 117 to better protect cord 133and give hose 117 a more streamlined appearance. The material movinginside hose 117 does not affect cord 133, nor does cord 133substantially affect the flow of material through hose 117. Thisconfiguration is illustrated in FIG. 13b. Alternatively, a conduit 134such as pressurized air lines or other types of fluid-conveying tubesmay be utilized inside hose 117 in addition to or in place of cord 133.A fitting 136 is used at each end of hose 117 to separate cord 133and/or conduit 134 from the fluid flow therein.

[0059] Hose 117 may be wrapped on a hose reel or hose rack 145 ofapparatus 11 (FIG. 13a) or extended therefrom (FIG. 15) depending on thelength of hose 117 required to reach the area of application. Also shownin FIG. 13a is the bottom frame 18 having handles 20, 22 that provideadditional pick-up points for apparatus 11. Bottom frame 18 also servesto protect the rotor and stator on pump 103, provides a skid surface onthe bottom of apparatus 11, and levels the machine when it isstationary.

[0060] In the example shown, hose 117 and cord 133 are interconnectedwith complementary connectors on a universal control handle (UCH) 135,which will be described in further detail below. UCH 135 is adapted towork in conjunction with many different types of tools, only one ofwhich is shown. UCH 135 is shown attached to a tool extension handle137. A flat taper 139 is mounted to the distal end of extension handle137 for making simultaneous, single-pass applications of drywallcompound and tape. Flat taper 139 enables hands-free embedding of thetape 143 in the compound as tape 143 is deployed from a tape dispenser141, which is shown mounted around the waist of the user. Water andcompound are loaded and mixed in mixing compartment 25 as previouslydescribed.

[0061] One skilled in the art will recognize that many othercombinations of tools and components are possible for finishingsurfaces, depending upon the particular application required. Forexample, the automated finishing system for interior surfaces also maybe used in conjunction with corner tapers, flat knives, box tools,automatic tapers, corner trowels, corner flushers, framed finishers,hawks, pans, texture spray guns, or painting equipment such as rollersor stomp mops. Moreover, any existing prior art tool or component may bereadily adapted or modified to work in conjunction with this system orin the manner that it was originally intended to be used.

[0062] Each of the tools and accessories, including UCH 135, arepreferably formed from stainless steel, titanium, and plastic. Thebladed tools are provided with quick and easy blade changes, and havereversible, double-life blades with electroless nickel coatings forimproved life. Depending upon the application, identical clampconnections can be made among suitable tools and accessories, and handtools can be fitted with extension handles when appropriate.

[0063] As shown in FIGS. 17 and 18, one version of the universal controlhandle (UCH) 135 comprises a rigid, ergonomic plastic grip 147 having amaterial feed port 149 with a quick connect coupling 151 on a proximalend, and a hand tool connection port 153 on a distal end. A line cap 155is mounted to UCH 135 to seal feed port 149 or coupling 151 when not inuse. Otherwise, UCH 135 may be connected to hose 117 (FIG. 15), anextension handle, or to a swivel 157 (FIG. 18) to allow tools to be usedin any direction and angle (see arrows), and with minimal strain on theoperator. UCH 135 also has an electrical connector 159 for distributingpower to an on/off control switch 161 and to a volume control switch163. Thus, control features for pump 103 are built into UCH 135. Theoperator can control on/off functions and the volumetric flow rate ofcompound remotely with UCH 135. All electrical components are sealed andmoisture resistant, and operate at low voltage for operator safety.

[0064] Referring now to FIGS. 19-21, a second embodiment of an automatedinterior finish apparatus 165 is shown. The primary difference betweenapparatus 165 and apparatus 11 is that apparatus 165 has two pumpingsystems 167, 169 that dispense material from an enlarged mixingcompartment 171. The dual pumps 167, 169 allow two operators tosimultaneously use apparatus 165 with no loss in performance orefficiency over apparatus 11. Mixing compartment 171 is provided withtwo pump inlets 173, 175 (FIG. 21) to feed the two pumping systems 167,169, each of which is aligned with force plates as described above.Apparatus 165 and apparatus 11 are otherwise operationally very similaror virtually identical. To facilitate better mobility for apparatus 165around the job site, a small wheel assembly 177 is provided on one endof the lower portion of frame 179. Wheel assembly 177 may be pivotallyrelocated into or out of contact with the ground supporting surface.

[0065] Referring now to FIGS. 22-24, a third embodiment of an automatedinterior finish apparatus 181 is shown. The primary difference betweenapparatus 181 and the previous two apparatus 11, 165 is that apparatus181 is much smaller with only one compartment 183 for mixing, clean-up,and tool storage. Compartment 183 feeds a single pump and is muchsmaller and lighter than the previous versions of the invention. The lid185 for compartment 183 has interior tool storage racks 187 (FIG. 23)that compensate for the lack of a separate storage compartment. Thereare preferably two folding tool storage racks 187 as shown forsupporting tools in compartment 183 when apparatus 181 is not inoperation. Because of its small size, apparatus 181 also has an externalwater tank 189 and hose rack 191 (FIG. 24) located on one side ratherthan beneath compartment 183.

[0066] Each of the aforementioned embodiments of the present inventionis also capable of being partially disassembled or broken down into twoseparate, lighter pieces with four easy steps. Ideally, the entireprocess takes less than two minutes and makes the units much moremaneuverable, thereby enabling two people to comfortably transport theentire machine to any area of a job site and then reassemble the unit.It is even possible for one person to load and unload the entire unitonto and off of a truck if necessary. These features make the presentinvention very accessible for maintenance purposes, allowing readyaccess to the undercarriage. As shown in FIGS. 26 and 27, the first twosteps are to unplug the electrical connections 195 and the waterconnections 197 that extend between, for example, the upper section 13of apparatus 11 and its lower section 15. The third step is to unscrewthe four wing nuts 193 (FIG. 25) that fasten upper and lower sections13, 15 together. In the final step, upper section 13 is unlatched andlifted off of lower section 15 to complete the separation of apparatus11 into two more easily movable pieces. The same steps may be followedfor breaking down apparatus 165 and 181.

[0067] An added benefit of separating the upper and lower sections isthe ability to interchange different upper and lower sections. Moreover,the upper sections can stand alone as a completely independent job sitemixer, even without the lower section. This allows the lower section tobe added later for full automation. Different variations of tank designscan be specified and added to the lower section very easily. The splitdesign allows easy and quick access to all the components located in thelower section, and greatly enhances the ease of maintenance.

[0068] The present invention has many advantages as the first trulyautomated machine for drywall finishing. All drywall and interiorapplications can be completed with the invention from start to finish.This automated interior finish system tremendously increases efficiencyover prior art systems and methods. The present invention not onlysupplies compound directly to the finishing tools, but it also reducesthe physical movements required to finish drywall. The smooth flow ofthe joint compound to the tools also improves the quality of the work onthe walls and ceiling with less floor splatter.

[0069] The mud pump is designed to eliminate jamming when dry compoundis added to the mixing tank. The unmixed compound is forced to mix withwater and residual mixed compound via a unique helical rotor or agitatorlocated adjacent to the pump inlet. Thus, the present inventionminimizes the formation of chunks of dried compound. Moreover, the jointcompound remains in a sealed tank and is not exposed to ambient airwhich would otherwise dry the compound before it is applied to the wall.Compounds which remain the air-tight chamber after use stay moist,thereby eliminating the need for clean-up on a daily basis.Additionally, the mixing auger and pump uniformly mix the material forultimate consistency. The result is a substantial increase in efficiencyover the most advanced systems currently available.

[0070] A positive displacement pump with a variable speed drive ensuresa smooth and uniform supply of material through the supply hose. Themodified ribbon mixer or auger keeps drywall, acoustic, or paintcompounds at a uniform consistency. Material is delivered to the toolsin a smooth, regulated flow. An on-board water system provides theability to add water and reduce material viscosity. Hose-to-tankconnection provides simultaneous compound mixing and circulation. Thewater sprayer is pressurized and has fingertip control to provideon-board clean-up. The water reservoir is conveniently located and hasan easy-access, non-detachable cover. The external hose rack provides aneat and efficient method of storage for the small diameter hose.

[0071] The machine if constructed from high quality stainless steel toeliminate corrosion and increase durability. Simple, easy-to-understandcontrols are conveniently located on a centralized panel. All electricalcomponents are moisture-sealed in a safe, non-conductive, durable cover.External, sealed, water-tight, resettable fuses also add safety andconvenience. The machine and console are protected by a tough one-inch,schedule-40 stainless steel pipe frame. A pair of pivotally-mountedtandem wheels provide excellent jobsite maneuverability and balance forthe machine. The unit easily pulls along behind the operator onnon-pneumatic tires that cannot flatten.

[0072] The machine is also provided with extension handles that storeneatly in four storage compartments for providing additional pick-uppoints and flexible jobsite handling. In addition, all components can bestored on or in the machine in convenient locations. For example, handtools are conveniently stored on two folding storage racks located inthe mixing tank lid. The air tight seals prevent compound from settingin the tools, thereby eliminating the need for clean-up betweenintermittent use. The larger units of the present invention haveadditional air-tight tanks for extra storage and clean-up. A lockinglatch on the exterior of the tank permits controlled access for toolprotection. The mixing chamber is electrically interlocked for operatorsafety. Finally, the present invention may be broken down into a moremanageable size in less than two minutes.

[0073] Another feature of the present invention is that it is readilyadaptable to work in conjunction with prior art traditional or standardtools such as box tools, tubular mud wipe down units, hawks, and pans.Such adaptation increases the speed and efficiency of application, whileallowing prior art tools to retain their manual usability. A continualfeed of mixed material is sent to standard tools for uninterruptedapplication so that they never have to be refilled. The mud reservoir onthe box tool fills during the time the tool is taken away from the walland moved to another joint. This system allows the box to apply mudpotentially faster than the pump can deliver, thereby allowing the pumpto run at a more continuous speed.

[0074] While the invention has been shown or described in only some ofits forms, it should be apparent to those skilled in the art that it isnot so limited, but is susceptible to various changes without departingfrom the scope of the invention.

What is claimed is:
 1. A system for automated finishing of interiorsurfaces, comprising: a compartment with a power mixer for mixingmaterial therein; a pumping system for pumping the material from thecompartment to a pumping system output; material delivery means fortransporting the material from the pumping system output to a terminalend; and application means for applying the material from the terminalend to a desired location.
 2. The system of claim 1, further comprisingan on-board water system for adding water to the compartment.
 3. Thesystem of claim 1 wherein the material delivery means is a hose.
 4. Thesystem of claim 1 wherein the material delivery means includeselectrical means for delivering power to the application means.
 5. Thesystem of claim 1, further comprising storage means for storingcomponents within the compartment.
 6. The system of claim 5 wherein thestorage means comprises a secondary compartment.
 7. The system of claim1 wherein the application means is a drywalling device.
 8. The system ofclaim 1, further comprising tape dispensing means for automaticallydispensing tape to the application means for application with thematerial.
 9. The system of claim 1 wherein the pumping system comprisestwo pumping system outputs for simultaneously applying the material attwo desired locations.
 10. The system of claim 1 wherein the applicationmeans has control means for remotely controlling operation of thepumping system from the terminal end.
 11. A system for automatedfinishing of interior surfaces, comprising: a base unit having amoisture-proof, sealable compartment with a power mixer forautomatically mixing material therein; a water system on the base unitfor adding water to the compartment; storage means mounted to the baseunit for storing components within the base unit; a pumping systemmounted to the base unit for automatically pumping mixed material fromthe compartment to a pumping system output; a conduit extending from thebase unit for transporting the mixed material from the pumping systemoutput to a terminal end; and application means for automatically andcontinuously applying the mixed material from the terminal end to adesired location.
 12. The system of claim 11 wherein the conduitincludes electrical means for delivering power from the base unit to theapplication means.
 13. The system of claim 11 wherein the storage meanscomprises a secondary compartment located adjacent to said compartmentfor cleaning and storing components.
 14. The system of claim 11 whereinthe application means is a drywall taping device.
 15. The system ofclaim 11, further comprising tape dispensing means for automaticallydispensing tape to the application means for application with the mixedmaterial.
 16. The system of claim 11 wherein the pumping systemcomprises two pumping system outputs for simultaneously applying themixed material at two desired locations.
 17. The system of claim 11wherein the application means has control means for remotely controllingoperation of the pumping system from the terminal end.
 18. A method ofautomatically finishing interior surfaces, comprising the steps of: (a)providing a system having a power mixing compartment, a pump, and anapplicator; (b) automatically mixing material in the power mixingcompartment; (c) pumping mixed material from the compartment to apumping system output; (d) transporting the mixed material from thepumping system output to the applicator; and then (e) applying the mixedmaterial with the applicator to a desired location.
 19. The method ofclaim 18 wherein step (b) comprises adding water to the power mixingcompartment and mixing the water with the material.
 20. The method ofclaim 18 wherein step (d) also comprises delivering power to theapplicator.
 21. The method of claim 18, further comprising the step ofstoring components within the compartment.
 22. The method of claim 18,further comprising the steps of cleaning components in a secondarycompartment and then storing the components in the secondarycompartment.
 23. The method of claim 18 wherein step (e) comprisesdrywalling.
 24. The method of claim 23, further comprising the step ofautomatically dispensing tape to the applicator for applying the tapewith the mixed material.
 25. The method of claim 18 wherein steps (d)and (e) comprises transporting the mixed material to two separateapplicators, and then simultaneously applying the mixed material withthe two applicators to two different locations.
 26. The method of claim18, further comprising the step of remotely controlling operation of thesystem from the applicator.